System and method for seat belt control

ABSTRACT

A system is provided for utilizing belt movement information in a motorized seat belt (MSB) control system algorithm to achieve better levels of comfort and safety. The MSB control system algorithm controls execution of multiple modes including a no friction mode, a stowage mode, a slack reduction mode, an out of position warning mode, a medium pull-back mode, and a high pull-back mode. The MSB control system algorithm also controls execution of a low power mode initiated after the other vehicle modules are put to sleep to provide the ability to stow the seat belt after the vehicle has been turned off for some period of time. The MSB control system algorithm also controls belt monitoring functions defined based on a buckle switch state that indicates the buckled or unbuckled state of the seat belt. Belt monitoring consists of belt movement being converted to counts based on a resolution provided by a belt movement sensor.

RELATED APPLICATIONS

This application is a divisional of application Ser. No. 11/701,530,filed Feb. 2, 2007, now pending, and claims priority to U.S. ProvisionalPatent Application No. 60/743,231, filed on Feb. 3, 2006, and titled “ASYSTEM AND METHOD FOR SEAT BELT CONTROL,” the disclosure of which isincorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The subject of the disclosure relates generally to a vehicle safetysystem. More specifically, the disclosure relates to a safety restraintsystem having a seat belt retractor driven by a motor and controlled byan electronic control unit.

BACKGROUND OF THE INVENTION

A vehicle generally contains automatic safety restraint devicesactivated during a vehicle crash to reduce occupant injury. The safetyof the occupant of a vehicle during a crash depends upon whether or notthe occupant is using the safety restraint system, and, if so, whetheror not the system is properly adjusted. Examples of automatic safetyrestraint devices include air bags, seat belt pretensioners, anddeployable knee bolsters. A more effective safety restraint systemcontrols the deployment force of airbags and the pretension of seatbeltsbased on detected characteristics of the seat occupant such as the sizeof the seat occupant. For example, when an adult is seated on thevehicle seat, the airbag can be deployed in a normal manner; however, ifa small child is seated on the seat, the airbag either should not bedeployed or should be deployed with a lower deployment force. Sensors ofvarious types are placed at locations in and around the vehicle todetect situational characteristics both inside the vehicle and outsidethe vehicle. The information from the sensors is input into one or morecontrol unit that controls the function of the safety restraint devices.

Restraint systems such as motorized seat belt (MSB) retractors havebecome standard equipment in modern automobiles. MSB retractors arewidely used to protect passengers from the impact produced during avehicle collision. Prior to a collision involving the vehicle, the MSBactuates a seat belt to protect the passenger. The MSB could be deployedbecause there are indications of an impending collision (an emergencysituation), based for example on a severe breaking or swerving of thevehicle or external sensor systems that predict a high probability of acollision or of a potential rollover. The MSB could also be deployed atlow force levels for comfort related reasons. As a result, the motorcontrol of the MSB may have two basic types of modes, comfort mode andsafety mode.

A MSB retractor includes a motor, typically electric, that operates toretract the seat belt in case of an emergency or to assist in theextraction or retraction when a passenger enters or exits the vehicle.The operation of the motor may be controlled by a signal generated by amicroprocessor. A control system algorithm and the associated logic areneeded to define the different safety and comfort modes that the MSBcontrol unit is designed to fulfill. Such an algorithm should receivemultiple sources of information available from various sensors such as abuckle status sensor, a seat track position sensor, a belt movementsensor, etc, and should utilize the information to improve the comfortlevel and the safety level of the vehicle occupant.

SUMMARY OF THE INVENTION

An exemplary embodiment of the invention provides a system and a methodfor utilizing belt movement information in a motorized seat belt (MSB)control system algorithm to achieve better levels of comfort and safety.For example, the MSB control system algorithm controls execution ofmultiple modes including a no friction mode, a stowage mode, a slackreduction mode, an out of position (OOP) warning mode, a mediumpull-back mode, and a high pull-back mode. The pull-back modes mayinclude multiple pull-back attempts to pull back the occupant in thesituation where the occupant has their hand between the belt and torsocausing continuous belt movement and a failure to lock the retractor.Each pull-back stage may be followed by a hold stage and ultimately arelease stage. The release stage may be characterized by calibrate-ableramp up and ramp down periods including a de-clutch period tocomfortably release the occupant while minimizing the power required bythe motor.

Additionally, the MSB control system algorithm includes a low power modefunctionality to reduce the amount of power required to maintain theresponsiveness of the control system. The MSB control system algorithminitiates the low power mode after the other vehicle modules are put tosleep. The purpose of the low power mode is to provide the ability tostow the seat belt after the vehicle has been turned off for some periodof time. The retraction is needed to prevent a limp seat belt from beingin the way of an occupant entering or exiting the vehicle. The low powermode is also needed when the occupant remains buckled for some period oftime during which the vehicle control system enters a full sleep mode,and the occupant subsequently unbuckles the seat belt. Using the lowpower mode, the MSB control system has the capability to wake up andassist the occupant in stowing the belt.

The MSB control system algorithm also controls belt monitoring functionsdefined based on a buckle switch state that indicates the buckled orunbuckled state of the seat belt. Belt monitoring consists of beltmovement being converted to counts based on a resolution provided by asensor. The sensor data is processed to determine whether the MSBcontrol system should initiate a slack reduction, occupant warning,stowage assist, pull-back, etc. Such decisions are determined based onthe belt monitoring zone and the retraction/extraction movement of theseat belt.

Other principal features and advantages of the invention will becomeapparent to those skilled in the art upon review of the followingdrawings, the detailed description, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The exemplary embodiments will hereafter be described with reference tothe accompanying drawings, wherein like numerals denote like elements.The objects shown in the figures may not be drawn to the same scale.

FIG. 1 depicts a side view of a first safety restraint system inaccordance with an exemplary embodiment.

FIG. 2 depicts a front view of a second safety restraint system inaccordance with an exemplary embodiment.

FIG. 3 is a block diagram illustrating functional components of amotorized seat belt (MSB) control system in accordance with an exemplaryembodiment.

FIG. 4 is a block diagram illustrating a mode sequence executed inanticipation of a collision event in accordance with an exemplaryembodiment.

FIG. 5 is a block diagram illustrating a high pull-back mode sequenceexecuted in anticipation of a collision event in accordance with anexemplary embodiment.

FIG. 6 illustrates a first motor current response having a singlepull-back stage in accordance with an exemplary embodiment.

FIG. 7 illustrates a second motor current response having two pull-backstages in accordance with an exemplary embodiment.

FIG. 8 illustrates a third motor current response having three pull-backstages in accordance with an exemplary embodiment.

FIG. 9 illustrates the first motor current response of FIG. 6 includingan indication of the characteristics of the hold stage in accordancewith an exemplary embodiment.

FIG. 10 illustrates the first motor current response of FIG. 6 includingan indication of the characteristics of the release stage in accordancewith an exemplary embodiment.

FIG. 11 is a block diagram illustrating functional components of a firstexemplary low power mode.

FIG. 12 illustrates a timing chart of the first exemplary low powermode.

FIG. 13 is a block diagram illustrating functional components of asecond exemplary low power mode.

FIG. 14 is a flow diagram illustrating exemplary operations of the firstexemplary low power mode in accordance with an exemplary embodiment.

FIG. 15 illustrates a timing chart of the second exemplary low powermode.

FIG. 16 illustrates monitoring zones of movement of a buckled belt inaccordance with an exemplary embodiment.

FIG. 17 is a flow diagram illustrating exemplary operations of thesecond exemplary low power mode in accordance with an exemplaryembodiment.

FIG. 18 is a flow diagram illustrating exemplary operations of the MSBcontrol system at wake-up in accordance with an exemplary embodiment.

FIG. 19 is a flow diagram illustrating exemplary operations inmonitoring a buckled seat belt of the MSB control system in accordancewith an exemplary embodiment.

FIG. 20 illustrates a first exemplary sequence of movement of the seatbelt relative to the monitoring zones of FIG. 16 in accordance with anexemplary embodiment.

FIG. 21 illustrates a second exemplary sequence of movement of the seatbelt relative to the monitoring zones of FIG. 16 in accordance with anexemplary embodiment.

FIG. 22 is a flow diagram illustrating exemplary operations in slackreduction of a buckled seat belt of the MSB control system in accordancewith an exemplary embodiment.

FIG. 23 illustrates a third exemplary sequence of movement of the seatbelt relative to the monitoring zones of FIG. 16 in accordance with anexemplary embodiment.

FIG. 24 illustrates monitoring zones of movement of a seat beltunbuckled at wake-up of the MSB control system in accordance with anexemplary embodiment.

FIG. 25 is a flow diagram illustrating exemplary operations inmonitoring an unbuckled seat belt of the MSB control system inaccordance with an exemplary embodiment.

FIG. 26 illustrates monitoring zones of movement of a seat belt of theMSB control system, wherein the seat belt is buckled at wake-up andsubsequently unbuckled, in accordance with an exemplary embodiment.

FIG. 27 is a flow diagram illustrating exemplary operations inmonitoring a seat belt status of the MSB control system in accordancewith an exemplary embodiment.

FIG. 28 is a flow diagram illustrating exemplary operations in stowageassistance of an unbuckled seat belt of the MSB control system inaccordance with an exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

With reference to FIG. 1, a safety restraint system 100 is shown. Safetyrestraint system 100 includes a bottom seat cushion 102, a back seatcushion 104, and an exemplary motorized seat belt (MSB) system 106.Exemplary MSB system 106 is of the three-point type and includes a seatbelt 107 and a MSB control system 120. Some or all of MSB control system120 may be located a distance from the seat belt 107. Seat belt 107 hasa first end 113 mounted to a bottom wall 124 of a vehicular body at afirst anchorage 118 and a second end mounted to a retractor containedwithin a retractor body 115. The retractor includes a spool about whichat least a portion of the seat belt 107 is wound for retraction andextraction movement. Thus, seat belt 107 is movable between the firstend 113 and the second end at the retractor. A shoulder anchor 113 ismounted to a wall 122 (shown with reference to FIG. 2) of the vehicularbody on the same side as that of first anchorage 118 as viewed from thefront of the vehicle and shown with reference to FIG. 2. Shoulder anchor113 includes a guide to allow movement of the seat belt 107therethrough. A tongue 114 is movably fitted to an intermediate portionof seat belt 107 and includes a guide that allows movement of the seatbelt 107 therethrough. Tongue 114 removably engages a buckle 116 mountedto bottom wall 124 at a second anchorage 126. When the tongue 114 isengaged with buckle 116, seat belt 107 is in a buckled state. When thetongue 114 is disengaged from buckle 116, seat belt 107 is in anunbuckled state. A sensor may be mounted in buckle 116 and/or tongue 114to detect the state of seat belt 107.

In use, a passenger pulls seat belt 107 out from the retractor andengages tongue 114 with buckle 116. As a result, seat belt 107 extendsacross the shoulder and waist of the passenger. In the buckled state, ifa collision occurs, seat belt 107 holds the passenger in the seat, thebasic mechanics of which are known to those skilled in the art. Forexample, a collision sensor detects a high probability of a collisionand sends a collision signal to MSB control system 120. In response, apretensioner mechanism begins retraction of seat belt 107. Seat belt 107contacts the waist and the upper part of the body of the passenger and,as a result, undergoes a load that causes a clamp mechanism to clampseat belt 107 thereby holding seat belt 107 in place. As a result, thepassenger is restrained with an appropriate force.

With reference to FIG. 3, functional components of the MSB controlsystem 120 are shown. In an exemplary embodiment, MSB control system 120includes a seat belt control algorithm 300, a memory 302, a power system304, a processor 306, sensors 308, a motor 310, and a spool 312. Seatbelt control algorithm 300 is an organized set of instructions that,when executed, cause MSB system 106 to comfortably and safely restrainthe passenger. Seat belt control algorithm 300 may be written using oneor more programming language, assembly language, scripting language,etc.

Memory 302 stores seat belt control algorithm 300 in addition to otherinformation. Memory technologies include, but are not limited to, randomaccess memory, read only memory, flash memory, etc. Power system 304provides power to the various components of MSB control system 120 andmay be a battery. Processor 306 executes instructions that may bewritten using one or more programming language, scripting language,assembly language, etc. The instructions may be carried out by a specialpurpose computer, logic circuits, or hardware circuits. Thus, processor306 may be implemented in hardware, fiuitiware, software, or anycombination of these methods. The teen “execution” is the process ofcarrying out the operation called for by an instruction. Processor 306executes seat belt control algorithm 300 and/or other instructions.

MSB control system 120 may have one or more processors and one or morememories that use the same or different implementing technologies. Seatbelt control algorithm 300 may be implemented in a single module or maybe distributed among multiple modules. The components of MSB controlsystem 120 may be housed separately or together and may interface usinga network. Components communicating in a network are connected bycommunication paths that may be wired or wireless. For example, MSBcontrol system 120 can be triggered via a message from an interface BUSsystem. The information required to trigger control system 120 may becarried over a communications bus, such as a controller area network(CAN) bus. In an exemplary embodiment, the CAN bus is a high-integrityserial data communications bus typically used for real-time applicationsthat can operate at rates up to 1 Megabits per second.

Sensors 308 detect conditions of MSB system 106. For example, a firstsensor may detect the buckled or unbuckled state of seat belt 107. Asanother example, a seat belt tension sensor may be used to monitor for awithdraw tension of seat belt 107. A withdraw tension is a tension inseat belt 107 that is indicative of an occupant's attempt to withdrawthe lap belt manually. Other sensors detect movement of spool 312 aboutwhich a portion of seat belt 107 retracts. Still other sensors detectmovement of the seat belt 107 to determine a direction and/or a speed ofthe movement. Yet other sensors may detect the weight of the passengerto determine a more optimal deployment of the seat belt pretensioners ofMSB system 106.

Motor 310 of the seat belt retractor may be used to drive spool 312 inboth the withdrawal (extraction) direction and the retraction direction.In general, the motor 310 is electric and is operated to rotate spool312 of the seat belt retractor in the withdrawal direction in responseto the tension sensor indicating a tension in seat belt 107 of at leastthe withdraw tension. When the tension in seat belt 107 drops below thewithdraw tension, motor 310 is stopped. When motor 310 is used to drivespool 312 in both the withdrawal direction and the retraction direction,the motor 310 is a reversible motor.

The motor control can be divided into six major modes which can beclassified under two main types of modes, comfort and safety. Comfortmodes include no friction mode and stowage mode. In no friction mode, nofriction is placed on seat belt 107 to impede its movement. In stowagemode, MSB control system 120 acts to assist the passenger in fullystowing seat belt 107 after use.

Safety modes include slack reduction mode, out of position (OOP) warningmode, medium pull-back mode, and high pull-back mode. Safety modes canbe initiated when MSB control system 120 is receiving full informationfrom the user interface bus. In general, the full information isreceived when the vehicle has been started, MSB control system 120 isfault free, and the occupant is buckled into safety restraint system100. The vehicle engine may be any of gas, hybrid, electric, etc.without limitation. In slack reduction mode, any slack in seat belt 107after buckling is removed. Additionally, any extra slack which may begenerated by an occupant leaning forward and then sitting back or by anoccupant moving the seat backwards also may be removed. In OOP warningmode, the occupant is out of position in the seat in some manner. In OOPwarning mode, a configurable number quick pull backs on the seat beltmay be generated by MSB control system 120 to warn the occupant when theoccupant is out of position for a configurable period of time. Forexample, the occupant may bend forward in the seat to pick something upfrom the floor of the vehicle. In medium pull-back mode, MSB controlsystem 120 operates to tighten seat belt 107 to hold the occupantcomfortably in the seat. In high pull-back mode, MSB control system 120operates to strongly pull the occupant back in the seat in anticipationof a crash event.

The pull-back modes consist of three main types of stages: pull-backstages (primary, secondary, and tertiary); hold stages; and a releasestage. A pull-back user interface command of MSB control system 120indicates two types of release strategies: 1) release based on a userinterface command; and 2) release based on a hold timer expiration. Withreference to FIG. 4, an exemplary sequence of mode progression is shownindicating a progression from no friction mode 400, to slack reductionmode 402 after movement of the occupant, to OOP warning mode 404 aftersignificant movement of the occupant, to medium pull-back mode 406, tohigh pull-back mode 408 after detection of a collision event.

With reference to FIG. 5, an exemplary sequence of stages is shown forexecuting either high pull-back mode 408 or medium pull-back mode 406. Aprimary pull-back stage 500 is initiated based on a safety controlcommand received over the user interface bus. The purpose of primarypull-back stage 500 is to first pull the occupant back in the seat andthen to maintain the tension in belt system 107 keeping the occupant inthe seat position. The release strategy could be based either on receiptof a release command or due to expiration of a hold timer. During a holdstage 502, the retractor is locked and waiting for a release pulse totransition to release stage 504. The retractor may be locked, forexample, using a mechanical lock or by maintaining a motor current. Ifduring hold stage 502, an unlocked retractor is sensed, for example,based on slack in the belt system 107, a secondary pull-back stage 506is initiated to remove the slack in order to lock the retractor again.During a hold stage 508, the retractor is locked and waiting for arelease pulse to transition to release stage 504. If an unlockedretractor is still sensed, a tertiary pull-back stage 510 is initiated.During a hold stage 512, the retractor is locked and waiting for arelease pulse to transition to release stage 504. High pull-back mode408, for example, occurs if the occupant had his hand between seat belt107 and his torso causing continuous belt movement upon withdrawal ofthe hand after primary pull-back stage 500 ends, which did not permitthe retractor to lock or caused slack in the seat belt. In suchscenarios, the need to initiate secondary pull-back stage 506 ortertiary pull-back stage 510 arises. Hold stages 502, 508, 512 may havethe same characteristics such as motor tension, duration, etc. or may bedifferent.

Hold stages 502, 508, 512 are terminated when a release command isreceive from the user interface bus or the hold timer expires. Aftercompletion of release stage 504, the motor control exits high pull-backmode and returns to no friction mode 400. For systems where belt monitorsensing and a retractor mechanical locking control system are notavailable, secondary pull-back stage 506 or tertiary pull-back stage 510may not be available. An exemplary retractor mechanical locking controlsystem is a solenoid controlled pawl. In these systems, only primarypull-back stage 500 may be applied.

With reference to FIG. 6, a first motor current response 600 is shownfor a primary pull-back stage 500, hold stage 502, and release stage 504execution. MSB control system 120 sends a command to motor 310 toinitiate a primary pull-back pulse 602, which transitions into a holdperiod 604. Hold period 604 ends at a time determined based on therelease strategy which, for example, may be a received release commandor expiration of a hold timer. At the termination of hold period 604,motor 310 initiates a release pulse 606.

With reference to FIG. 7, a second motor current response 700 is shownfor a primary pull-back stage 500, hold stage 502, secondary pull-backstage 506, hold stage 508, and release stage 504 execution. MSB controlsystem 120 sends a command to motor 310 to initiate a primary pull-backpulse 702, which transitions into a hold period 703. Hold period 703ends at a time determined based on the release strategy which, forexample, may be a received release command or expiration of a holdtimer. At the termination of hold period 703, motor 310 may initiate asecondary pull-back pulse 704 if belt slack exists, which transitionsinto a hold period 705. Hold period 705 ends at a time determined basedon the release strategy which, for example, may be a received releasecommand or expiration of a hold timer. At the termination of hold period705, motor 310 initiates a release pulse 706.

With reference to FIG. 8, a third motor current response 800 is shownfor a primary pull-back stage 500, hold stage 502, secondary pull-backstage 506, hold stage 508, tertiary pull-back stage 510, hold stage 512,and release stage 504 execution. MSB control system 120 sends a commandto motor 310 to initiate a primary pull-back pulse 802, whichtransitions into a hold period 803. Hold period 803 ends at a timedetermined based on the release strategy which, for example, may be areceived release command or expiration of a hold timer. At thetermination of hold period 803, motor 310 may initiate a secondarypull-back pulse 804 if belt slack exists. Secondary pull-back pulse 804transitions into a hold period 805. Hold period 805 ends at a timedetermined based on the release strategy which, for example, may be areceived release command or expiration of a hold timer. At thetermination of hold period 805, motor 310 may initiate a tertiarypull-back pulse 806 if belt slack exists. Tertiary pull-back pulse 806transitions into a hold period 807. Hold period 807 ends at a timedetermined based on the release strategy which, for example, may be areceived release command or expiration of a hold timer. At thetermination of hold period 807, a release pulse 808.

With reference to FIG. 9, characteristics of hold stage 502 are shown.Hold stage time period 901 extends from the peak of primary pull-backpulse 602 to the initiation of release pulse 606. Hold stages 502, 508,512 are entered after finishing the respective pull-back stage 500, 506,510. A first time period 903 is a calibrate-able delay period duringwhich MSB control system 120 continues to energize the solenoid as anattempt to lock the retractor and to guarantee an engaged pawl of thespool. Continuing to energize the solenoid protects in the scenariowhere the solenoid is activated for a period of time, but, because theoccupant is moving backward and the motor current is still high andtrying to move the belt monitor in the retraction direction, the pawldisengages and the retractor becomes unlocked. The solenoid is energizedduring first time period 903 determined to guarantee locking during suchbounce back conditions.

Belt monitoring includes sensing of belt movement and the conversion ofthe sensed belt movement to “counts” based on the resolution provided bythe belt movement sensor. Thus, a “count” indicates an amount of beltmovement based on the resolution provided by the belt movement sensor.The sensor data is processed to determine whether seat belt controlalgorithm 300 should initiate a slack reduction, an occupant warning, astowage assist, etc. Such decisions are determined based on adetermination of a belt monitoring zone and decision logic describedwith reference to FIGS. 18, 22, 25, 27, and 28.

A second time period 904 represents the time period that startsimmediately after first time period 903. During second time period 904,MSB control system 120 assumes that the retractor is locked. Once theretractor is locked, and during second time period 904 both theretractor and the hardware sensing mechanism are designed to guaranteethat any extraction of seat belt 107 does not generate more than a firstnumber of counts, for example, three counts. After the retractor islocked, and during second time period 904 both the retractor and thehardware sensing mechanism are designed to guarantee that moving asecond number of counts in the retraction direction results in a freespool or unlocked retractor. During second time period 904, if the firstnumber of consecutive counts in the extraction direction or the secondnumber of consecutive counts in the retraction direction are detected, afree spool or unlocked retractor is identified, and a secondarypull-back pulse 704, 804 (or tertiary pull-back pulse 806) is initiatedas shown with reference to FIGS. 7 and 8. Line 902 indicates a tensionon seat belt 107 during the pull-back, hold, and release stages. A thirdtime period 905 extends from the start of hold stage 604 until the endof first time period 903.

With reference to FIG. 10, characteristics of release pulse 606, 706,808 are shown. One of primary pull-back pulse 602, secondary pull-backpulse 704, or tertiary pull-back pulse 806 are indicated as pull-backpulse 1001. Hold period 1008 extends from the peak of pull-back pulse1001 to initiation of a release pulse 1002. The primary objective ofrelease pulse 1002 is to release the locked retractor smoothly withoutcausing any “pull” feeling to the occupant. In order to release a lockedretractor, the spool rotates in a retraction direction, and the motorcurrent may be higher than the maximum current produced during anyprevious pull-back stage. For this reason, the release pulse is designedto have a quick ramp up of the motor current to a level near the motorcurrent levels achieved during pull-back pulse 1001 before release ofthe pawl. At the initiation of release pulse 1002, a first motor currentresponse period 1004, includes a ramp up of the motor current level to afirst motor current level 1030 during which no belt retraction isexpected. First motor current level 1030 is a calibrate-able percentageof the maximum motor current level produced during pull-back pulse 1001.In an exemplary embodiment, the percentage is 90%. A first slope 1014 ofthe ramp up of the motor current level to first motor current level 1030is calibrate-able to provide an approximate step shape without too muchdiscomfort to the seat occupant. Approximating a step reduces the amountof energy consumed by the system during first motor current responseperiod 1004. If the hardware senses the first number of consecutivecounts in the extraction direction or the second number of consecutivecounts in the retraction direction, the retractor is assumed to beunlocked and the remainder of release pulse 1002 is cancelled and adeclutch pulse follows.

After achieving first motor current level 1030, a second motor currentresponse period 1005 ramps up to near a maximum motor current level. Thepawl is primarily released during second motor current response period1005 due to spool retraction. Second motor current response period 1005includes a first ramp up to a second motor current level 1032. A secondslope 1016 of the ramp up of the motor current level to second motorcurrent level 1032 is calibrate-able. The second slope 1016 generally issmaller than first slope 1014 because the occupant is expected to feelthe release during this phase. Second motor current response period 1005includes a second ramp up to a third motor current level 1034 that is amaximum motor current level. A third slope 1018 of the ramp up of themotor current level to third motor current level 1034 is calibrate-able.A switch to third slope 1018 occurs at second motor current level 1032if release of the pawl has not been sensed. The third slope 1018generally is larger than second slope 1016 because greater motor torqueis expected from a more pronounced change in the motor current. Forexample, third slope 1018 may be a step. Alternatively, under conditionswherein a maximum motor current always releases a retractor at secondslope 1016, third slope 1018 can be set to the same value as secondslope 1016 for improved comfort by preventing a second pull feeling onthe occupant. The motor current level remains at the maximum motorcurrent for a calibrate-able delay period to guarantee that the pawl hasbeen disengaged. The period may be set to zero to reduce the amount ofenergy consumed by the system during the ramp up portion.

After completion of second motor current response period 1005, a thirdmotor current response period 1006 ramps down to a fourth motor currentlevel 1028 based on a calibrate-able fourth slope 1020. During thirdmotor current response period 1006, the occupant is released slowly.Without such a controlled release, the occupant could experience anabrupt release. After achieving fourth motor current level 1028, asecond ramp down to a fifth motor current level 1026 based on acalibrate-able fifth slope 1022 occurs. Fifth motor current level 1026is determined to avoid bringing the motor current below a certain levelbecause the occupant may move the motor in the extraction direction suchthat the motor begins working as a generator. A calibrate-able delayperiod follows until the motor current is reversed to declutch themotor. The calibrate-able delay period is designed to allow a releasedoccupant to continue to relax their body in the extraction directionwhile still maintaining the spool in the clutched state. A clutchedspool has more friction in the gear system than a declutched spool. Themore friction provides benefits because it slows down an occupant'sextraction process. Otherwise, if a declutch is performed too soon afterthe release pulse, the initial force may cause the occupant to “jerk”forward. After the delay period, a fourth motor current response period1007 includes the current reversal. The calibrate-able feature of thedeclutch ramp adds comfort to the release pulse during the motordeclutch stage. The current level at which the reversed current isstarted is a calibrate-able sixth motor current level 1024. The duration1010 of release pulse 1002 extends from the start of first motor currentresponse period 1004 and extends until the completion of fourth motorcurrent response period 1007.

Multiple power modes include a sleep mode, a low power mode, and anormal operation mode. The MSB control unit may enter a low current modeafter the other vehicle modules are put to sleep. The low current modeprovides the ability to stow seat belt 107 after the vehicle has beenturned off for some period of time. The retraction is needed to preventa limp seatbelt from being in the way of an occupant entering or exitingthe vehicle. The low current mode also provides the capability to wakeup and assist the occupant in stowing the seat belt 107, for example,when the occupant remains buckled for some period of time, the vehiclegoes to full sleep, and the occupant then unbuckles the seat belt 107.As another scenario, an occupant extracts the belt as an attempt tobuckle the seat belt 107, but changes their mind. As a result, MSBcontrol system 120 preferably stows seat belt 107 even though there wasno buckle transition to use as a wakeup signal. As a result, the lowpower mode itself provides a method of alerting MSB control system 120to the potential for a stowage retraction. The low current mode may notactually stow seat belt 107. The awareness of belt movement provided bythe low power mode brings the MSB control unit to its full-awake state.Once awake, the stowage retraction occurs.

The low power mode ends after a calibrate-able time period. An exemplarytime period is ten minutes. After the time period, the MSB control unitenters full sleep mode if no activity is identified. Instead of timingthe period, a microcomputer may update a counter periodically anddetermine the completion of the time period based on the counterequaling a specific value. For example, a counter may be updated eachsecond. When the counter reaches 600 counts, a ten minute time periodhas expired. In order for the microcomputer to update a counter, a typeof random access memory (RAM) or read only memory (ROM) may be used tomaintain the counter. Preferably, RAM used to avoid wearing out the ROMdue to continuous rewriting. As a result, the RAM of the microcomputeris always alive during the low power mode, which means that V_(DD) poweris always available. As known to those skilled in the art, other timerimplementations may be employed.

With reference to FIG. 11, functional components of a first exemplarylow power mode are shown. A battery 1100 provides power to a wake-upcontrol 1104 of control unit 1102. A voltage V_(DD)=ON is provided to amicrocomputer 1108 of control unit 1102. A voltage V₂=OFF is provided toother control unit elements 1106 when in the first exemplary low powermode. With reference to FIG. 12, microcomputer 1108 receives a commandfrom MSB control system 120 to enter a stop mode at a first time t₁₂₁.In response, microcomputer 1108 enters a pseudo stop mode for atransition time period 1202 before entering the full sleep mode. Duringtransition time period 1202, microcomputer 1108 enters stop mode fromfirst time t₁₂₁ at which the command is received until a second timet₁₂₂ at which microcomputer 1108 wakes up and commands the remainingcomponents of MSB control system 120 to wake-up. Until a third timet₁₂₃, microcomputer 1108 monitors the sensor edges using a standardsoftware interface to identify any belt activity. A time period 1204includes the time span from first time t₁₂₁ to third time t₁₂₃. Asequence of time periods 1204 is repeated until the transition timeperiod 1202 expires. If no activity has occurred, full sleep mode isentered. This periodic sensing approach presents a periodic duration oftime during which MSB control system 120 is unaware of belt movement.

With reference to FIG. 14, exemplary operations performed atmicrocomputer 1108 are shown. In an operation 1400, microcomputer 1108receives a command to go to stop mode. In an operation 1402, a flag isset in memory indicating entry into the low power mode. In an operation1404, a wake-up control monitor (watchdog timer) is disabled. In anoperation 1406, the wake-up control is placed in stop mode. In anexemplary embodiment, V_(DD)=ON and V₂=OFF to place the wake-up controlin stop mode. Microcomputer 1108 enters pseudo stop mode in an operation1408. A wait period until second time t₁₂₂ occurs during an operation1410. An exemplary second time t₁₂₂ is approximately 300 milliseconds(ms). In an operation 1412, microcomputer 1108 wakes up. In an operation1414, microcomputer 1108 commands the remaining components of controlunit 1102 to wake-up. In an operation 1416, microcomputer 1108 monitorsfor belt movement. In operation 1418, a determination of belt movementis performed. If belt movement is detected, processing continues atoperation 1800, and MSB control system 120 remains in full wake-up mode.If belt movement is not detected, in operation 1420, a determination ofwhether or not transition time period 1202 has expired is performed. Iftransition time period 1202 has expired, MSB control system 120 entersfull sleep mode in an operation 1422. If transition time period 1202 hasnot expired, processing continues at operation 1406.

With reference to FIG. 13, functional components of a second exemplarylow power mode are shown. A battery 1300 provides power to a wake-upcontrol 1306 of control unit 1302. A voltage V_(DD)=ON is provided to abelt monitor sensing interface 1308 of control unit 1302. Belt monitorsensing interface 1308 receives belt movement information from beltmonitor 1304. Voltage V_(DD)=ON also is provided to microcomputer 1310of control unit 1302. A voltage V₂=OFF is provided to other control unitelements 1312 when in the second exemplary low power mode.

With reference to FIG. 15, microcomputer 1310 receives a command fromthe MSB control system 120 to enter a stop mode at a first time t₁₅₁. Inresponse, microcomputer 1108 enters a pseudo stop mode for a transitiontime period 1502 before entering the full sleep mode. During transitiontime period 1502, microcomputer 1108 enters the stop mode from firsttime t₁₅₁ at which the command is received until a second time t₁₅₂ atwhich microcomputer 1108 wakes up and serves the watch dog timer. Untila third time t₁₅₃, microcomputer 1108 monitors the sensor edges using astandard software interface to identify any belt movement activity. Atime period 1504 includes the time span from first time t₁₅₁ to thirdtime t₁₅₃. A sequence of time periods 1504 is repeated until thetransition time period 1502 expires. If no activity has occurred, fullsleep mode is entered. Belt monitor sensing interface 1308 continuouslymonitors for belt movement. If movement is detected, an interrupt 1314is sent to microcomputer 1310.

With reference to FIG. 17, exemplary operations performed at controlunit 1302 are shown. In an operation 1700, microcomputer 1310 receives acommand to go to stop mode. In an operation 1702, a flag is set inmemory indicating entry into the low power mode. In an operation 1704,the wake-up control monitor period is set. In an operation 1706, thewake-up control is placed in standby mode. In an exemplary embodiment,V_(DD)=ON and V₂=OFF to place the wake-up control in standby mode.Microcomputer 1310 enters pseudo stop mode in an operation 1708. A waitperiod until second time t₁₅₂ occurs during an operation 1710. Anexemplary second time t₁₅₂ is approximately 350 ms. In an operation1712, microcomputer 1310 wakes up and serves the watch dog timer beforeit expires. In an operation 1714, microcomputer 1108 commands thewake-up control to check the status of belt movement. In operation 1716,a determination of whether or not transition time period 1502 hasexpired is performed. If transition time period 1502 has expired, MSBcontrol system 120 enters full sleep mode in an operation 1718. Iftransition time period 1502 has not expired, processing continues atoperation 1708.

In an operation 1720, microcomputer 1108 receives an interrupt 1314 frombelt monitor sensing interface 1308. In an operation 1722, microcomputer1310 wakes up. In an operation 1724, microcomputer 1310 monitors forbelt movement for a monitoring time period and services the watchdogtimer. In operation 1726, a determination of belt movement is performed.If belt movement is detected, processing continues at operation 1800,and MSB control system 120 remains in full wake-up mode. If beltmovement is not detected, in operation 1728, a determination of whetheror not the monitoring time period has expired is performed. If themonitoring time period has expired, processing continues at operation1708. If the monitoring time period has not expired, processingcontinues at operation 1724.

During the second exemplary low power mode, the wake-up control providespower to microcomputer 1310 and the belt movement sensing circuitry andshuts off power to the other control unit elements 1312. The beltmonitor sensing interface 1308 interrupts the microcomputer 1310 whenbelt movement is detected based on detected movement of the edges.Microcomputer 1301 keeps track of the count of these edges afterreceiving the interrupt. Microcomputer 1301 continuously captures thenumber of edges resulting from any belt movement and triggers atransition into full awake mode once a specified number of edges havebeen captured. After the system is running in full awake mode, a stowageretraction may be performed. Using the second exemplary low power mode,there are no time periods during which the system is unaware of beltmovement. Such an arrangement may increase the mode power requirements,however, over those of the first exemplary low power mode.

When buckled, the belt monitoring function defines a position A thatindicates a “buckled park” position based on the belt movement sensordata. If the belt is buckled when the system wakes up, the buckled beltmonitoring logic and thresholds are active. When unbuckled, the beltmonitoring function defines a position E that indicates an “unbuckledpark” position based on the sensor data. Thus, the state of seat belt107 when the MSB system wakes up determines whether the buckled orunbuckled belt monitoring logic is active. If the belt is buckled whenthe system wakes up, seat belt 107 has not been unbuckled during thecurrent wake period meaning that position E has not been defined forseat belt 107. Any transition from buckled to unbuckled uses stowageassist logic based on position A instead of position E. Positions A andE may be recorded in memory 302.

With reference to FIG. 18, belt monitoring logic is specified in termsof the buckle switch state. Wake-up of the MSB control system 120 occursin an operation 1800. In an operation 1802, a determination is made asto whether or not tongue 114 is engaged with buckle 116. If tongue 114is engaged with buckle 116, processing continues at operation 1900 forbuckled belt monitoring. If tongue 114 is not engaged with buckle 116, adetermination is made as to whether or not seat belt 107 is moving, inan operation 1804. If seat belt 107 is moving, processing continues atoperation 1802. If seat belt 107 is not moving, belt position E isdefined for an unbuckled position, and processing continues at operation2500 for unbuckled belt monitoring.

The belt monitoring logic monitors events where the belt is retracted orextracted across a threshold that determines the action required of theMSB system 120. The retractions or extractions may or may not be motorcontrolled. Instead, the retractions may be caused by a retractor springforce and/or a manual assist from the seat occupant. Without theseretraction sources, seat belt 107 may remain at the position to whichseat belt 107 has been extracted. An unbuckled MSB system may notperform a stowage assist retraction.

Two scenarios for entering the buckled belt monitoring logic include: 1)entry at wake-up with the belt in a buckled state, and 2) a transitionof the belt from a unbuckled state to an buckled state. The buckled beltmonitoring is used to determine when an OOP warning mode or slackreduction mode is initiated. Slack reduction mode generally may beinitiated in the following situations: 1) the belt becomes buckled whenposition A is not defined, for example, after MSB wakeup in unbuckledmode; 2) whenever a smaller position A is detected, for example, when aprevious position A is not the actual buckled park position A; 3) whenan occupant returns from leaning forward, but not far enough to haveinitiated the OOP warning mode. MSB system 120 waits for an occupant,who is leaning forward, to finish what they are doing and to return toan upright seated position before initiating a slack reduction.

With reference to FIG. 16, zones and thresholds used in the beltmonitoring logic for a buckled seat belt are defined based on deltasfrom defined position A. Position A is defined based on a number of beltmovement counts while the belt is buckled. Position A defines thesmallest belt movement count when the belt is buckled with no slack inthe belt. In reality, position A may or may not represent a no slackposition. As a result, position A is updated each time upon completionof a slack reduction mode or any pull-back mode. Variation in position Aexists based on occupant size, seat position, D-ring position, etc.Based on a determination of position A, five calibrate-able thresholdsA−, A+, B, C, and D are defined. Threshold A− is the low threshold for abuckled park zone 1600 that includes the variation in position A.Threshold A+ is the high threshold for buckled park zone 1600 thatincludes the variation in position A. The difference between position Aand threshold A− and A+ may be the same or different. Threshold B is aslack reduction trigger threshold defined for an occupant activity zone1602. Occupant activity zone 1602 defines a zone of belt movement overwhich the passenger may move the seat belt without initiating an alertor warning or slack reduction. Threshold C is an extraction alertthreshold that identifies the transition from occupant activity zone1602 to an extraction alert zone 1604. Threshold D is a warningthreshold that identifies the transition from extraction alert zone 1604to a warning zone 1606. Belt movement across the thresholds triggersvarious response mechanisms of seat belt control algorithm 300.

Threshold A− defines the lower bound of buckled park zone 1600. Anyspring force retraction across this threshold may start the slackreduction timer. Belt slack can be produced by the occupant moving theseat backward or adjusting the shoulder anchor 113 or tongue 114. Seatbelt 107 may retract based on assistance from the occupant or retractorspring force alone. Threshold A+ defines the upper bound of buckled parkzone 1600. Any retraction of the belt across threshold A+ indicates areturn to the “buckled park” zone. Any slack reduction or warning timersactive when threshold A+ is crossed are stopped, and the alert status ofthe system is cleared.

Threshold C defines the point of extraction that causes the beltmonitoring function to be “alert” for potential MSB slack reductionand/or occupant warning scenarios that may be required. Extractingacross this threshold alone may not start a retraction timer, but may bethe first gate required in the logic leading to a slack reduction orwarning pulse activation. Threshold D defines the point of beltextraction where a warning pulse timer starts. If the timer has beenstarted, and the belt retracts across threshold D, the warning timer isstopped.

Threshold B provides a level of hysteresis between the point where thesystem becomes alert to the belt extraction and the point where thesystem decides to activate the slack reduction timer. The hysteresissupports cases where an occupant bends forward to perform some task andthen returns to his originally seated position. The system preventsslack reduction attempts until the occupant has returned, or nearlyreturned, to his originally seated position thereby avoiding anannoyance to the occupant when he is consciously bending forward toperform a task. Retraction across threshold B after extraction acrossthreshold C starts the slack reduction timer and extraction acrossthreshold B stops the slack reduction timer.

With reference to FIG. 19, exemplary operations of a buckled beltmonitoring algorithm are shown starting at an operation 1900. In anoperation 1902, a determination insures that seat belt 107 remains in abuckled state. If seat belt 107 does not remain in a buckled state,processing continues at operation 2500. If seat belt 107 remains in abuckled state, an operation 1904 determines if belt position A isdefined. If belt position A is not defined, processing continues atoperation 1918. If belt position A is defined, an operation 1906determines if seat belt 107 has retracted across threshold A−. If seatbelt 107 has retracted across threshold A−, processing continues atoperation 1918. If seat belt 107 has not retracted across threshold A−,an operation 1908 determines if seat belt 107 has extracted acrossthreshold C. If seat belt 107 has not extracted across threshold C,processing continues at operation 1904. If seat belt 107 has extractedacross threshold C, an operation 1910 determines if seat belt 107 hasretracted across threshold A−. If seat belt 107 has retracted acrossthreshold A−, processing continues at operation 1918. If seat belt 107has not retracted across threshold A−, an operation 1912 determines ifseat belt 107 has retracted across threshold A+. If seat belt 107 hasretracted across threshold A+, processing continues at operation 1904.If seat belt 107 has not retracted across threshold A+, an operation1914 determines if seat belt 107 has extracted across threshold D. Ifseat belt 107 has extracted across threshold D, processing continues atoperation 1938. If seat belt 107 has not extracted across threshold D,an operation 1912 determines if seat belt 107 has retracted acrossthreshold B. If seat belt 107 has not retracted across threshold B,processing continues at an operation 1942. If seat belt 107 hasretracted across threshold B, processing continues at operation 1918.

In operation 1918, a slack reduction timer is started and processingcontinues at operation 1920. Operation 1920 determines if belt positionA is defined. If belt position A is not defined, processing continues atoperation 1930. If belt position A is defined, an operation 1922determines if seat belt 107 has retracted across threshold A−. If seatbelt 107 has retracted across threshold A−, processing continues atoperation 1930. If seat belt 107 has not retracted across threshold A−,an operation 1924 determines if seat belt 107 has retracted acrossthreshold A+. If seat belt 107 has extracted across threshold A+,processing continues at operation 1932. If seat belt 107 has notretracted across threshold A+, an operation 1926 determines if seat belt107 has extracted across threshold D. If seat belt 107 has extractedacross threshold D, processing continues at operation 1932. If seat belt107 has not extracted across threshold D, an operation 1928 determinesif seat belt 107 has extracted across threshold B. If seat belt 107 hasextracted across threshold B, processing continues at operation 1936. Ifseat belt 107 has not extracted across threshold B, an operation 1930determines if the slack reduction timer has expired. If the slackreduction timer has expired, processing continues at operation 2200 toattempt to reduce the slack in seat belt 107. If the slack reductiontimer has not expired, processing continues at operation 1920.

In an operation 1932, the slack reduction timer is stopped andprocessing continues at operation 1904. In an operation 1936, the slackreduction timer is stopped and processing continues at operation 1942.In an operation 1942, a warning timer is stopped. In an operation 1938,a warning timer is started and processing continues at operation 1940.An operation 1940 determines if seat belt 107 has extracted acrossthreshold D. If seat belt 107 has not extracted across threshold D,processing continues at operation 1942. If seat belt 107 has extractedacross threshold D, an operation 1944 determines if a warning timer hasexpired. If the warning timer has expired, in an operation 1946, ahaptic warning may be initiated. If the warning timer has not expired,processing continues at operation 1940.

A slack reduction attempt may result in the belt being stopped before ithas been retracted to its currently defined buckled park position A.This may be caused by obstruction from any part of the occupant, or anyobject the occupant may be handling. A calibrate-able number of retryattempts to return the belt to its buckled park position A may beperformed. In an exemplary embodiment, a retry counter is selectablebetween zero and three. With reference to FIG. 22, exemplary operationsof a buckled belt slack reduction algorithm are shown starting at anoperation 2200. In an operation 2201, motor 310 is sent a command toretract seat belt 107 to reduce any slack that may exist based on seatoccupant movement. An operation 2202 determines if retraction of seatbelt 107 is complete. If retraction of seat belt 107 is not complete,processing continues at operation 2201. If retraction of seat belt 107is complete, an operation 2204 determines if seat belt 107 has retractedacross threshold A+. If seat belt 107 has retracted across threshold A+,processing continues at operation 2210. If seat belt 107 has notretracted across threshold A+, an operation 2206 determines if a retrycounter is zero. If the retry counter is zero, processing continues atoperation 2210. If the retry counter is not zero, the retry counter isdecremented in an operation 2208 and processing continues at operation2201. In operation 2210, belt position A is updated and processingcontinues at operation 2212. In operation 2212, thresholds A−, A+, B, C,and D are updated relative to position A and processing continues atoperation 2214. In operation 2214, the retry counter is re-set to aspecified pre-defined value. Thus, position A is updated to reflect beltposition changes due to an occupant moving the seat backwards/forwards,adjusting a belt shoulder anchor, holding/removing a bag, puttingon/taking off coat, etc.

With reference to FIG. 20, a first exemplary sequence of movement of theseat belt relative to the monitoring zones of FIG. 16 is shown forillustration of the exemplary operations of the buckled belt monitoringalgorithm and of the buckled belt slack reduction algorithm. Seat belt107 is extracted across thresholds A+, B, and C. At a first trigger timet₂₀₁, a system alert occurs upon extraction across threshold C.Subsequently, seat belt 107 is retracted across thresholds C and B. At asecond trigger time t₂₀₂, a slack reduction timer is started uponretraction across threshold B. Subsequently, seat belt 107 is retractedacross threshold A+ at a third trigger time t₂₀₃. At third trigger timet₂₀₃, the slack reduction timer is stopped, and the system alert iscleared.

With reference to FIG. 21, a second exemplary sequence of movement ofthe seat belt relative to the monitoring zones of FIG. 16 is shown forfurther illustration of the exemplary operations of the buckled beltmonitoring algorithm and of the buckled belt slack reduction algorithm.Seat belt 107 is extracted across thresholds A+, B, and C. At a firsttrigger time t₂₁₁, a system alert occurs upon extraction acrossthreshold C. Subsequently, seat belt 107 is retracted across thresholdsC and B. At a second trigger time t₂₁₂, a slack reduction timer isstarted upon retraction across threshold B. Subsequently, seat belt 107is extracted across threshold B, at a third trigger time t₂₁₃, withoutretraction across threshold A+. At third trigger time t₂₁₃, the slackreduction timer is stopped because the occupant is not returning to thebuckled park zone, but the system remains alerted. Subsequently, seatbelt 107 is retracted across threshold B, at a fourth trigger time t₂₁₄,and the slack reduction timer is restarted.

With reference to FIG. 23, a third exemplary sequence of movement of theseat belt relative to the monitoring zones of FIG. 16 is shown forfurther illustration of the exemplary operations of the buckled beltmonitoring algorithm and of the buckled belt slack reduction algorithm.Seat belt 107 is extracted across thresholds A+ and B. Subsequently,seat belt 107 is retracted across threshold B. The slack reduction timeris not started because the system is not in an alert state becausethreshold C was not crossed. MSB system 120 remains in occupant activityzone 1602.

Unbuckled belt monitoring is used to determine when a stowage assistretraction is initiated by the MSB control system 120. Two scenarios forentering the unbuckled belt monitoring logic 2500 are 1) entry atwake-up as shown with reference to FIGS. 18, and 2) a transition of thebelt from a buckled state to an unbuckled state as shown with referenceto FIG. 19. With reference to FIG. 24, zones and thresholds used in thebelt monitoring logic for an unbuckled seat belt are defined based ondeltas from defined position E. Position E is defined based on a numberof belt movement counts while the belt is unbuckled and not moving.Based on a determination of position E, three calibrate-able thresholdsE−, E+, and F are defined. Threshold E− is the low threshold for anunbuckled park zone 2402 that includes a variation in position E.Retraction across threshold E− indicates that the current position Evalue is not the position where the belt is fully retracted. Retractingacross threshold E− starts a stowage assist timer. Threshold E+ is thehigh threshold for an unbuckled park zone 2402 that includes a variationin position E. Retraction across threshold E+ indicates that the belthas returned to unbuckled park zone 2402. As a result, the stowageassist timer is stopped and reset. Threshold F defines a transitionposition retraction that defines an upper bound for an assist fromunbuckled zone 2404. Retraction across threshold F triggers the start ofthe stowage assist timer.

Unbuckled park position E is used to define the position of seat belt107 when it is fully retracted. Unbuckled park position E may alsorepresent anywhere between shoulder anchor 113 and buckle 116. As aresult, the value of position E is updated based on sensor data takenwhen an MSB stowage retraction comes to a stop. If seat belt 107 isunbuckled at wake-up, and determined not to be moving, the current beltposition is defined as position E.

With reference to FIG. 26, zones and thresholds used in the beltmonitoring logic for an unbuckled seat belt when the belt is buckled atwake-up are defined based on a delta from defined position A. Based on adetermination of position A, one additional calibrate-able threshold Gis defined. A stowage assist mode may be initiated in a number ofsituations. First, the stowage assist mode may be initiated when thebelt becomes unbuckled when unbuckled park position E is not yetdefined, for example, when the MSB wakesup in buckled mode. Spring forceretracts the belt a pre-defined distance G counts from buckled parkposition A. Afterwards, MSB system 120 initiates stowage assist mode.The parameter G is used to generate a no activity zone immediately afterunbuckled, to support a situation such as an occupant unbuckling thebelt, but holding it without letting the belt go. In this case, thestowage assist mode starts when the belt is G counts away from buckledpark position A to prevent stowage assist mode pulling the buckle fromthe occupant's hands upon unbuckled state change. Second, the stowageassist mode may be initiated when the belt becomes unbuckled andunbuckled park position E is defined. Spring force retracts the belt apre-defined distance F counts from unbuckled park position E.Afterwards, MSB system 120 initiates stowage assist mode. Position F isused to make sure the occupant is ready for the belt to be retracted,but because the unbuckled park position E is already defined, F also isdefined and is used instead of G. Position F and position G may or maynot be the same value. Third, the stowage assist mode may be initiatedwhenever a smaller unbuckled park position E is detected to provide forresetting of position E.

With reference to FIG. 25, exemplary operations of an unbuckled beltmonitoring algorithm are shown starting at an operation 2500. Anoperation 2504 determines if belt position E is defined. If beltposition E is not defined, processing continues at operation 2506. Ifbelt position E is defined, an operation 2508 determines if seat belt107 has retracted across threshold E−. If seat belt 107 has retractedacross threshold E−, processing continues at operation 2512. If seatbelt 107 has not retracted across threshold E−, an operation 2510determines if seat belt 107 is currently within assist from unbuckledzone 2404. If seat belt 107 is not currently within assist fromunbuckled zone 2404, processing continues at operation 2504. If seatbelt 107 is currently within assist from unbuckled zone 2404, processingcontinues at operation 2512. Assist from unbuckled zone 2404 allows fora no activity zone to exist when the belt is extracted across thresholdF and prevents the stowage retraction from attempting to pull the beltout of the occupant's hand when the buckle process has not beencompleted.

Operation 2506 determines if seat belt 107 is currently within assistfrom buckled zone 2602. If seat belt 107 is not currently within assistfrom buckled zone 2602, processing continues at operation 2504. If seatbelt 107 is currently within assist from buckled zone 2602, processingcontinues at operation 2512. In operation 2512, an assist timer isstarted and processing continues in an operation 2518. Operation 2518determines if seat belt 107 is being extracted. If seat belt 107 isbeing extracted, processing continues at operation 2514. If seat belt107 is not being extracted, an operation 2520 determines if beltposition E is defined. If belt position E is defined, an operation 2516determines if seat belt 107 is currently within unbuckled park zone2402. If seat belt 107 is currently within unbuckled park zone 2402,processing continues at operation 2514. If seat belt 107 is notcurrently within unbuckled park zone 2402, processing continues atoperation 2522. If belt position E is not defined, processing continuesat operation 2522. Operation 2522 determines if the assist timer hasexpired. If the assist timer has not expired, processing continues atoperation 2518. If the assist timer has expired, processing continues atoperation 2524. In operation 2524, a stowage assist retraction isinitiated and processing continues at operation 2800. In an operation2514, the assist timer is stopped and reset and processing continues atoperation 2504.

With reference to FIG. 27, a buckled state is continuously monitored byMSB control system 120 when the unbuckled state is defined to identifyif a passenger engages tongue 114 with buckle 116. Additionally, anunbuckled state is continuously monitored by MSB control system 120 whenthe buckled state is defined to identify if a passenger disengagestongue 114 from buckle 116. An operation 2700 determines if seat belt107 is buckled. If seat belt 107 is not buckled, processing continues atoperation 2700 to continue monitoring. If seat belt 107 is buckled, theassist timer is stopped in an operation 2702 and processing continues atoperation 1900 to initiate buckled belt monitoring.

With reference to FIG. 28, exemplary operations of a stowage assistalgorithm are shown starting at an operation 2800. In an operation 2801,motor 310 is sent a command to retract seat belt 107 to assist instowage of seat belt 107. Processing continues at operation 2802.Operation 2802 determines if belt position E is defined. If beltposition E is not defined, processing continues at operation 2814. Ifbelt position E is defined, an operation 2804 determines if retractionof seat belt 107 is complete. If retraction of seat belt 107 is notcomplete, processing continues at operation 2804. If retraction of seatbelt 107 is complete, an operation 2806 determines if seat belt 107 hasretracted across threshold E+. If seat belt 107 has retracted acrossthreshold E+, processing continues at operation 2814. If seat belt 107has not retracted across threshold E+, an operation 2808 determines if aretry counter is zero. In an exemplary embodiment, a retry counter isselectable between zero and three. If the retry counter is zero,processing continues at operation 2814. If the retry counter is notzero, the retry counter is decremented in an operation 2810, andprocessing continues at operation 2801. In operation 2814, belt positionE is updated, and processing continues at operation 2816. In operation2816, thresholds E−, E+, and F are defined relative to position E, andprocessing continues at operation 2818. In operation 2818, the retrycounter is re-set to a specified pre-defined value.

A change in belt direction from retraction to extraction after thestowage assist timer is started may cause the timer to be stopped andreset. Such a change in direction indicates that the occupant isattempting to extract more belt after the belt monitoring logic hasdetermined that a stowage retraction situation exists. In this case, thestowage retraction is aborted.

The foregoing description of exemplary embodiments of the invention havebeen presented for purposes of illustration and of description. It isnot intended to be exhaustive or to limit the invention to the preciseform disclosed, and modifications and variations are possible in lightof the above teachings or may be acquired from practice of theinvention. For example, although the safety restraint system has beendescribed with reference to a continuous loop three-point safetyrestraint system having a single seat belt retractor, the concepts areequally applicable to a three-point safety restraint system having dualretractors, to a two point safety restraint system having only a lapbelt or a shoulder belt, to a four-point safety restraint, etc.Additionally, though the safety restraint system has been described withreference to a passenger car, the concepts are applicable to any type ofvehicle and to any type of seat whether mounted in a vehicle or not. Theembodiments were chosen and described in order to explain the principlesof the invention and as practical applications of the invention toenable one skilled in the art to utilize the invention in variousembodiments and with various modifications as suited to the particularuse contemplated. It is intended that the scope of the invention bedefined by the claims appended hereto and their equivalents.

1. A seat belt system, the system comprising: a seat belt; a retractorcapable of retracting the seat belt; and a controller operably coupledwith the retractor to control movement of the seat belt, wherein thecontroller is configured (a) to receive a command to enter a stop mode;(b) to switch off a first set of components of the controller to enter alow power mode of operation; (c) after expiration of a first timeperiod, to switch on a first component of the first set of components tocheck for expiration of a second time period; (d) to monitor formovement of the seat belt; (e) if no belt movement is detected,repeating (b)-(d) until expiration of the second time period; and (f) ifno belt movement is detected before expiration of the second timeperiod, to switch off the first set of components of the controller toenter a sleep mode of operation.
 2. A method of transitioning a seatbelt controller to a sleep mode, the method comprising: (a) receiving acommand to enter a stop mode; (b) switching off a first set ofcomponents of the seat belt controller to enter a low power mode ofoperation; (c) after expiration of a first time period, switching on afirst component of the first set of components to check for expirationof a second time period; (d) monitoring for movement of a seat belt; (e)if no belt movement is detected, repeating (b)-(d) until expiration ofthe second time period; and (f) if no belt movement is detected beforeexpiration of the second time period, switching off the first set ofcomponents of the seat belt controller to enter a sleep mode ofoperation.
 3. The method of claim 2, wherein (c)-(d) further comprise,after expiration of the first time period, switching on the first set ofcomponents of the seat belt controller and monitoring for movement ofthe belt monitor during a third time period, wherein (b)-(d) is repeatedafter expiration of the third time period without detection of beltmovement.
 4. The method of claim 2, wherein the second time period isapproximately ten minutes.
 5. The method of claim 2, wherein the firsttime period is less than approximately 350 milliseconds.
 6. The methodof claim 2, further comprising, if belt movement is detected beforeexpiration of the second time period, switching on the first set ofcomponents of the seat belt controller to enter a full awake mode ofoperation.
 7. A seat belt system, the system comprising: a buckle; aseat belt including a tongue, wherein the tongue is capable of engagingwith the buckle; a retractor, wherein the retractor is capable ofretracting the seat belt under control of an actuator; and a controllercapable of communicating with the actuator to control movement of theseat belt, wherein the controller is configured (a) to determine abuckle status of the seat belt; (b) if the determined buckle status isbuckled, to define a buckled value based on a first position of the seatbelt; (c) to define a plurality of thresholds based on the definedbuckled value; (d) to monitor movement of the seat belt to determine aseat belt position; (e) to compare the determined seat belt position tothe plurality of thresholds; and (f) to perform an action based on thecomparison of (e).
 8. A method of controlling a seat belt, the methodcomprising: (a) determining a buckle status of a seat belt; (b) if thedetermined buckle status is buckled, defining a buckled value based on afirst position of the seat belt; (c) defining a plurality of thresholdsbased on the defined buckled value; (d) monitoring movement of the seatbelt to determine a seat belt position; (e) comparing the determinedseat belt position to the plurality of thresholds; and (f) performing anaction based on the comparison of (e).
 9. The method of claim 8, whereinthe action is at least one of stowing the seat belt, sending a warningto a seat occupant, and reducing a slack in the seat belt.
 10. Themethod of claim 8, further comprising: (g) attempting to reduce a slackin the seat belt; (h) determining a first seat belt position after (g);(i) comparing the determined first seat belt position to a firstthreshold, wherein the first threshold is defined as the buckled valueplus an extraction value; (j) if the determined first seat belt positionis less than the first threshold, replacing the defined buckled valuewith the determined first seat belt position; and (k) re-defining theplurality of thresholds based on the replaced buckled value.
 11. Themethod of claim 10, further comprising: (l) if the determined first seatbelt position is greater than the first threshold, repeating (g)-(k).12. The method of claim 11, further comprising: (m) repeating (l) apredetermined number of times unless the determined first seat beltposition is less than the first threshold; and (n) if the determinedfirst seat belt position is greater than the first threshold after (m),replacing the defined buckled value with the determined first seat beltposition.
 13. The method of claim 8, wherein the plurality of thresholdscomprises a first threshold, wherein the first threshold is defined asthe buckled value plus an extraction value, and further wherein anextraction of the seat belt across the first threshold starts a warningpulse timer.
 14. The method of claim 13, wherein a retraction of theseat belt across the first threshold stops the warning pulse timer. 15.The method of claim 13, further comprising, after expiration of thewarning pulse timer, initiating a haptic warning to a user of the seatbelt.
 16. The method of claim 8, wherein the plurality of thresholdscomprises a first threshold, wherein the first threshold is defined asthe buckled value plus an extraction value, and further wherein aretraction of the seat belt across the first threshold starts a slackreduction timer.